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Advisor(s)
Abstract(s)
A BorgWarner propôs a implementação de um teste funcional intermédio com
o objetivo de diminuir sucata na etapa final da linha e reduzir o tempo de ciclo
do teste final (gargalo ou bottleneck). Para estabelecer quais os testes a realizar e
determinar qual das placas testar, foi essencial perceber a função de cada placa, o
que já é testado na linha de produção e qual das placas seria a melhor opção para
ser testada, considerando a relação custo/benefício. Após uma análise profunda, a
equipa de engenharia optou por testar a placa de controlo, dada a sua importância
crítica no funcionamento do inversor.
Devido ao potencial impacto financeiro na aquisição de uma máquina que rea lizará o teste intermédio, é de extrema importância garantir com clareza o que irá
ser testado e a viabilidade na implementação de uma nova máquina. Para colmatar
isto, foi desenvolvido uma prova de conceito, isto porque além de ser um investi mento significativamente menor e mais rápido, torna-se essencial neste contexto,
uma vez que proporciona uma oportunidade de avaliar com precisão as características e funcionalidades da máquina de teste intermédio, permitindo testar alguns
pontos críticos, verificando a eficácia, confiabilidade e desempenho antes de realizar
o investimento financeiro na aquisição do equipamento completo. Em complemento
a isto, a prova de conceito possibilita ainda a identificação de quaisquer desafios ou
limitações que possam surgir durante a implementação do equipamento, uma vez
que na fábrica não se realiza, até ao momento, testes funcionais às placas isoladas.
A eficácia e a confiabilidade confirmadas nesta fase preliminar abrem agora caminho para a realização de um teste intermédio industrial, que irá reduzir o tempo de
ciclo do gargalo e melhorar significativamente a qualidade e eficiência da linha de
produção, revelando-se num investimento altamente lucrativo para a empresa.
Em suma, a BorgWarner atingiu com sucesso os objetivos estabelecidos inicial mente com a implementação do teste intermédio, uma vez que a abordagem adotada
não só demonstrou ser economicamente vantajosa, como também reforçou a eficiência e a qualidade dos processos de produção
BorgWarner proposed the implementation of an intermediate functional test with the aim of reducing scrap at the final stage of the production line and decreasing the cycle time of the final test (bottleneck). To determine which tests to conduct and decide which of the boards to test, it was essential to understand the function of each board, what is already tested in the production line, and which board would be the best option for testing, considering the cost-benefit relationship. After a thorough analysis, the engineering team chose to test the control board due to its critical importance in the inverter’s operation. Due to the potential financial impact of acquiring a machine that will perform the intermediate test, it is of utmost importance to ensure clarity regarding what will be tested and the feasibility of implementing a new machine. To address this, a proof of concept was developed because, in addition to being a significantly lower and faster investment, it is essential in this context as it provides an opportunity to accurately assess the features and functionalities of the intermediate test ma chine, allowing for testing some critical points, checking effectiveness, reliability, and performance before making the financial investment in acquiring the complete equipment. In addition to this, the proof of concept also allows for the identification of any challenges or limitations that may arise during the equipment implementa tion, as functional tests of isolated boards have not been performed in the factory until now. With the introduction of this test, it is possible to reduce scrap in the last stage of the production line since it increases the ability to detect faults in a board that was only functionally tested in the final test. Furthermore, it also enables a reduction in the cycle time of the bottleneck by anticipating exclusive tests on the control board conducted in the final processes.
BorgWarner proposed the implementation of an intermediate functional test with the aim of reducing scrap at the final stage of the production line and decreasing the cycle time of the final test (bottleneck). To determine which tests to conduct and decide which of the boards to test, it was essential to understand the function of each board, what is already tested in the production line, and which board would be the best option for testing, considering the cost-benefit relationship. After a thorough analysis, the engineering team chose to test the control board due to its critical importance in the inverter’s operation. Due to the potential financial impact of acquiring a machine that will perform the intermediate test, it is of utmost importance to ensure clarity regarding what will be tested and the feasibility of implementing a new machine. To address this, a proof of concept was developed because, in addition to being a significantly lower and faster investment, it is essential in this context as it provides an opportunity to accurately assess the features and functionalities of the intermediate test ma chine, allowing for testing some critical points, checking effectiveness, reliability, and performance before making the financial investment in acquiring the complete equipment. In addition to this, the proof of concept also allows for the identification of any challenges or limitations that may arise during the equipment implementa tion, as functional tests of isolated boards have not been performed in the factory until now. With the introduction of this test, it is possible to reduce scrap in the last stage of the production line since it increases the ability to detect faults in a board that was only functionally tested in the final test. Furthermore, it also enables a reduction in the cycle time of the bottleneck by anticipating exclusive tests on the control board conducted in the final processes.
Description
Keywords
Intermediate test PCB final test cycle time control board inverter functional test BGA PIC CAN electric vehicles bottleneck